Club Car XRT 950 2009 Page 8 Maintenance And Service Manual Download

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Test Procedures ......................................................................................................................................... 11-12

SECTION 12 – ELECTRICAL COMPONENTS

.................................................................................................. 12-1

Starter and Starter Solenoid ......................................................................................................................... 12-1
Neutral Switch ............................................................................................................................................. 12-1

Neutral Switch Removal ........................................................................................................................... 12-1
Neutral Switch Installation ........................................................................................................................ 12-2

Carburetor Solenoid..................................................................................................................................... 12-2

Carburetor Solenoid Removal................................................................................................................... 12-2
Carburetor Solenoid Installation ................................................................................................................ 12-3

Voltage Regulator ........................................................................................................................................ 12-3

Voltage Regulator Removal ...................................................................................................................... 12-3
Voltage Regulator Installation ................................................................................................................... 12-4

Warning Lights ............................................................................................................................................ 12-5

Warning Light Removal ............................................................................................................................ 12-5
Warning Light Installation ......................................................................................................................... 12-5

Fuel Gauge/Hour Meter ............................................................................................................................... 12-6

Fuel Gauge/Hour Meter Removal ............................................................................................................. 12-6
Fuel Gauge/Hour Meter Installation........................................................................................................... 12-6

Key Switch .................................................................................................................................................. 12-7

Key Switch Removal ................................................................................................................................ 12-7
Key Switch Installation ............................................................................................................................. 12-7

Light Switch................................................................................................................................................. 12-7

Light Switch Removal .............................................................................................................................. 12-7
Light Switch Installation............................................................................................................................ 12-8

Front Differential Disable Switch (Optional).................................................................................................... 12-8

Front Differential Disable Switch Removal ................................................................................................. 12-8
Front Differential Disable Switch Installation .............................................................................................. 12-8

Front Differential Limit Switch ....................................................................................................................... 12-8

Front Differential Limit Switch Removal ..................................................................................................... 12-9
Front Differential Limit Switch Installation .................................................................................................. 12-9

Fuse ........................................................................................................................................................... 12-9

Fuse Removal ......................................................................................................................................... 12-9
Fuse Installation ...................................................................................................................................... 12-9

Fuel Level Sending Unit ..............................................................................................................................12-10

Fuel Level Sending Unit Removal ............................................................................................................12-10
Fuel Level Sending Unit Installation .........................................................................................................12-10

Ignition Coil And Charge Coil.......................................................................................................................12-10

Ignition Coil And/or Charge Coil Removal.................................................................................................12-10

Oil Pressure Sensor.................................................................................................................................... 12-11
Headlights.................................................................................................................................................. 12-11

Headlight Bulb Removal.......................................................................................................................... 12-11
Headlight Bulb Installation ....................................................................................................................... 12-11

Wire Harness Diodes ..................................................................................................................................12-12

Diode Removal.......................................................................................................................................12-12
Diode Installation ....................................................................................................................................12-12

Battery .......................................................................................................................................................12-12

General Information ................................................................................................................................12-13

SECTION 13 – ENGINE

................................................................................................................................... 13-1

Engine Removal .......................................................................................................................................... 13-1
Engine Installation ....................................................................................................................................... 13-5
Engine RPM Adjustment – Through Early-2012 Model Year ........................................................................... 13-5

Vehicle Creep.......................................................................................................................................... 13-5
Idle Speed Adjustment ............................................................................................................................. 13-6
High Speed Adjustment ........................................................................................................................... 13-9

Engine RPM Adjustment – From Early-2012 Model Year ............................................................................... 13-11

Vehicle Creep......................................................................................................................................... 13-11
Idle Speed Adjustment ............................................................................................................................ 13-11
High Speed Adjustment ..........................................................................................................................13-14

Governor Lever Reset Adjustment ...............................................................................................................13-16

Page vi

2009-2012 XRT 950 Maintenance and Service Manual

Summary of Contents for XRT 950 2009

Page 1: ...2009 2012 XRT 950 Maintenance and Service Manual XRT 950 4x2 XRT 950 4x4 XRT 950 EX 4x4 Manual Number 103472727 Edition Code 1208H 011G 1...

Page 2: ......

Page 3: ...who want to learn more about our products For more information contact your local dealer or Club Car s Technical Services department for a list of upcoming classes This manual covers all aspects of ty...

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Page 5: ...Impact Damage Deformations 4 2 Minor Scratches and Surface Blemishes 4 2 Small Scratches That Cannot Be Buffed Out 4 3 Touch Up Paint Color Chart 4 3 Gouges Punctures Tears Large Scratches and Abrasio...

Page 6: ...al Information 6 1 Troubleshooting 6 1 Brake System Troubleshooting 6 1 Brake System Inspection 6 4 Hydraulic and Mechanical Components 6 6 Brake Fluid Reservoir 6 7 Brake Hose Replacement 6 7 Brake P...

Page 7: ...Removal 9 5 Rear Wheel Bearings and Hub Installation 9 6 Wheel Alignment 9 7 SECTION 10 PERIODIC MAINTENANCE 10 1 General Information 10 1 Pre Operation and Daily Safety Checklist 10 2 Performance In...

Page 8: ...on 12 8 Front Differential Limit Switch 12 8 Front Differential Limit Switch Removal 12 9 Front Differential Limit Switch Installation 12 9 Fuse 12 9 Fuse Removal 12 9 Fuse Installation 12 9 Fuel Leve...

Page 9: ...on 16 5 SECTION 17 TRANSAXLE AND HALFSHAFTS 17 1 General Information 17 1 Ratios 17 1 Transaxle Removal 17 1 Transaxle Installation 17 6 Rear Halfshaft Removal 17 7 Rear Halfshaft Installation 17 7 Sh...

Page 10: ...iven Clutch Installation 18 14 Inner Clutch Cover 18 14 Inner Clutch Cover Removal 18 14 Inner Clutch Cover Installation 18 15 SECTION i INDEX Page viii 2009 2012 XRT 950 Maintenance and Service Manua...

Page 11: ...th Danger is RED WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death The color associated with Warning is ORANGE CAUTION A CAUTION with the safety aler...

Page 12: ...enclosed cab Do not run the engine in a parked vehicle without proper cab ventilation Move to fresh air if you feel nausea headache dizziness drowsiness or weakness Follow the procedures exactly as s...

Page 13: ...cle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes When servicing the vehicle with part of the vehic...

Page 14: ...cable 2 Remove positive battery cable Connect battery cables in reverse order 821 Figure 1 1 Battery Cable Removal 795 Figure 1 2 4x4 Drive Warning CONNECTING THE BATTERY GASOLINE VEHICLES 1 Connect...

Page 15: ...s Hydraulic brake system brake pads and discs on each wheel with separate hand operated park brake BODY CHASSIS Frame Chassis Box tube steel Side and rear body Polypropylene Cargo bed Powder coated st...

Page 16: ...gal 3 79 L Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml Fuel tank unleaded gasoline 5 2 gallons 19 7 L TIRE PRESSURE All terrain tread Carlisle All Trail II 25 x 9 12 and 25 x 11 12 Front Rear 1...

Page 17: ...Registration Warranties MODEL IDENTIFICATION SERIAL NUMBER The serial number of the vehicle is printed on a bar code decal mounted on the frame below the steering wheel Example SD0601 123456 Figure 3...

Page 18: ...a away from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle WARNING Turn the key switch to the OFF position remove the key and lea...

Page 19: ...he closed OFF position Figure 3 2 Page 3 3 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 823 Figure 3 2 Fuel Shut...

Page 20: ...se of the choke can result in a fouled spark plug and engine failure 5 Place the Forward Reverse handle in the NEUTRAL position Crank the engine until fuel is pumped into the carburetor and the fuel l...

Page 21: ...he park brake Chock the front wheels 3 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 4 If removing wheel loosen the rear wheel lug nuts 5 Lift re...

Page 22: ...near batteries When jumping from a booster battery make the final connection the negative cable Do not jump start or charge a frozen or damaged battery Unplug charger before connecting or disconnectin...

Page 23: ...remove the cable from the negative terminal of the disabled vehicle battery first Next remove the other end of the cable from the negative terminal of the booster battery Then remove the cable from t...

Page 24: ......

Page 25: ...ectrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure The seats of the vehicle will last longer with proper cleaning To pr...

Page 26: ...om minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in...

Page 27: ...up paint available from Club Car Service Parts see following color chart apply paint to the scratch Multiple layers of paint may be required to fill the scratch 4 Allow paint to dry completely approx...

Page 28: ...ter ends of front fascia 1 Remove the two torx head screws that secure the front of the each fender to the under side outer ends of the fascia Figure 4 1 Page 4 4 1063 Figure 4 2 Front Fascia Removal...

Page 29: ...nt Fascia Removal pulling fascia forward 4 Grip fascia lift slightly to disengage the front fascia hook and pull fascia forward slightly to expose the headlight wiring Figure 4 4 Page 4 5 1053 Figure...

Page 30: ...he lower corner of the fascia using two torx head screws Tighten screws to 22 in lb 2 5 N m FRONT COWL REMOVAL 1062 Figure 4 6 Front Cowl Removal under side of outer ends of front fascia 1 Disconnect...

Page 31: ...Page 4 7 1157 Figure 4 9 Front Cowl Removal unbolting upper fascia mounting frame 5 Remove upper front fascia mounting frame bolts Figure 4 9 Page 4 7 1137 Figure 4 10 Front Cowl Removal separating co...

Page 32: ...es of cowl from dash Figure 4 11 Page 4 8 1139 Figure 4 12 Front Cowl Removal disengage cowl from fender grooves 8 Grip cowl lift and disengage edges of cowl from fender grooves Figure 4 12 Page 4 8 1...

Page 33: ...ts mounted in instrument panel 5 At engine loosen choke cable clamp Figure 4 14 Page 4 9 and disengage choke cable Figure 4 15 Page 4 9 979 Figure 4 14 Choke Cable Clamp loosen 980 Figure 4 15 Choke C...

Page 34: ...4 3 Loosen instrument panel by removing four screws that secure the top of the instrument panel to the top of the instrument panel support frame Figure 4 18 Page 4 10 and removing the two bolts that s...

Page 35: ...free front fender 7 Remove front fender from vehicle FRONT FENDER INSTALLATION 1 Install front fender in the reverse order of removal 2 Tighten front fender hardware to 22 in lb 2 5 N m UNDER PEDAL CL...

Page 36: ...ck pin 1 located at the driver side cargo bed hinge 2 Figure 4 23 Page 4 12 2 Remove seat bottom from vehicle 3 Locate the center closeout panel Flex closeout panel to disengage front lower lip that r...

Page 37: ...emoval remove side panel bolts 974 Figure 4 26 Closeout Panel Removal unclip from lower seat support frame 7 Rotate each outer closeout panel until it can be easily removed from the seat back support...

Page 38: ...29 Page 4 15 3 Loosen the cross tube hardware 12 13 15 16 and forward support hardware 5 4 Remove the top rear cross tube hardware and the top rear cross tube 14 from the vehicle 5 Remove the top fron...

Page 39: ...BODY AND TRIM ROPS Roll Over Protective Structure 4 1 15 16 15 x 14 14 16 11 18 9 10 12 13 21 20 5 8 7 K 00107 eps Figure 4 29 ROPS 2009 2012 XRT 950 Maintenance and Service Manual Page 4 15...

Page 40: ...llowing NOTE NOTE Make sure the bolt heads are oriented to the inside of the ROPS structure It may be necessary to tap the ROPS with a rubber mallet in order for it to align properly 5 Loosely secure...

Page 41: ...king Pin 2 Bed Locking Pin Holes K 00221 Figure 4 32 Bed Locking Pin 1 Raise the cargo bed and engage the cargo bed lock pin 1 located at the driver side cargo bed hinge 2 Figure 4 32 Page 4 17 1073 F...

Page 42: ...l in the reverse order of removal 2 Tighten side panel bolts to 22 in lb 2 5 N m Tighten cargo bed rubber bumper bolts to 84 in lb 9 5 N m 3 Install ROPS See ROPS Installation on page 4 16 UNDER SEAT...

Page 43: ...NDER See General Warning on page 1 2 REAR FENDER REMOVAL 1 Raise the cargo bed and engage the cargo bed lock pin located at the driver side cargo bed hinge Figure 4 37 Page 4 19 2 Remove the four bolt...

Page 44: ...on but do not engage the cargo bed latch 4 Remove the two cargo bed mounting lock nuts washers and pivot bolts 5 With the help of an assistant lift the cargo bed and remove from vehicle CARGO BED INST...

Page 45: ...not to damage any components as a result of the drilling operation 3 Disconnect the Z shaped end 1 of the accelerator cable from the pedal Figure 5 2 Page 5 1 See following NOTE NOTE If the accelerat...

Page 46: ...is taller and grooved 7 Loosen cable clamp that secures accelerator cable Figure 5 6 Page 5 2 This will allow additional travel so that the cable can be disconnected at pedal 982 Figure 5 5 Detach Acc...

Page 47: ...oup assembly to chassis Figure 5 8 Page 5 3 and Figure 5 9 Page 5 3 1190 Figure 5 8 Accelerator Pedal Removal pedal assembly hardware 1191 Figure 5 9 Accelerator Pedal Removal pedal assembly hardware...

Page 48: ...ight and adjust if necessary Figure 5 10 Page 5 4 3 Tighten pedal group hardware to 180 in lb 20 N m 4 Adjust accelerator cable See Accelerator Cable Adjustment Through Early 2012 Model Year on page 5...

Page 49: ...5 11 Bed Locking Pin 1023 Figure 5 12 Remove Exhaust Heat Shield 5 Detach accelerator cable extension spring s Figure 5 13 Page 5 5 See following NOTE NOTE Later models have a second spring attached...

Page 50: ...h 9 5 mm 1 Install cable through chassis along original route 2 If installing accelerator cable CC P N 103433101 skip this step If installing replacement accelerator cable CC P N 103789401 perform the...

Page 51: ...sabling the Vehicle on page 1 3 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 3 Raise the cargo bed and secure with the bed locking pin See Car...

Page 52: ...el Year ACCELERATOR AND BRAKE PEDAL GROUP 2315 Figure 5 17 Fully Turn Throttle Bellcrank Until It Contacts Tab 2316 Figure 5 18 Correct Throttle Bellcrank Position With Accelerator Pedal To Floor Page...

Page 53: ...ut rivets and carefully pull the panel out and down over the pedals Figure 5 20 Page 5 10 CAUTION Be sure not to damage any components as a result of the drilling operation 3 Disconnect the Z shaped e...

Page 54: ...essary 6 Slide accelerator pedal 3 out of pedal bracket 5 ACCELERATOR PEDAL INSTALLATION FROM EARLY 2012 MODEL YEAR 1 Installation is reverse of removal procedure 2 Check return spring height and adju...

Page 55: ...2 Bed Locking Pin Holes K 00221 Figure 5 22 Bed Locking Pin 1023 Figure 5 23 Remove Exhaust Heat Shield 4 Loosen the jam nuts that secure cable to engine Figure 5 24 Page 5 11 5 Unhook spring end of a...

Page 56: ...shield 5 Place a 3 4 inch 19 mm thick spacer between the accelerator pedal and the floorboard 6 Push accelerator pedal down against the spacer and hold 7 Fully open the engine throttle wide open thro...

Page 57: ...AKE PEDAL GROUP Accelerator Cable Adjustment From Early 2012 Model Year 5 2511 Figure 5 26 Correct Throttle Bellcrank Position With Accelerator Pedal To Floor 2009 2012 XRT 950 Maintenance and Service...

Page 58: ...ling operation 3 Remove rue pin and clevis pin securing master cylinder push rod to brake pedal Figure 5 28 Page 5 14 1179 Figure 5 27 Remove Closeout Panel 1193 Figure 5 28 Disconnect Master Cylinder...

Page 59: ...TMENT 1 Loosen the master cylinder rod and clevis jam nut 2 Rotate the master cylinder rod to extend or retract the clevis and brake pedal to the desired position 3 Tighten the jam nut to 168 in lb 19...

Page 60: ......

Page 61: ...OEM parts TROUBLESHOOTING See General Warning on page 1 2 BRAKE SYSTEM TROUBLESHOOTING The procedures used in making the checks provided in the following troubleshooting guide can be found in the ref...

Page 62: ...ged hydraulic lines Replace brake lines as required See Brake Hose Replacement on page 6 7 Hard pedal excessive pedal pressure is required to stop the vehicle Frozen master cylinder piston or bent rod...

Page 63: ...Replace the brake discs See Brake Discs on page 6 14 Binding brake pedal Lubricate and adjust See Accelerator and Brake Pedal Group Section All brakes drag Soft or swollen rubber parts caused by incor...

Page 64: ...15 seconds The pedal should not continue dropping when pressed with a steady amount of pressure If the pedal goes to the floor inspect the hydraulic system for leaks and repair any worn or damaged co...

Page 65: ...ed or have excessive scores or heat checks Each disc should be at least 0 150 inches 3 8 mm at the thinnest point Inspect each caliper They should not hold the brake pads tightly against the disc when...

Page 66: ...out Dirt can quickly damage the system NOTE Mark hoses for correct installation if factory markings are not found Contain and dispose of any leaking fluid in an environmentally safe manner and accordi...

Page 67: ...bottom of the reservoir or other evidence of contamination CAUTION Use only DOT 5 silicone brake fluid Use of any other type brake fluid is not recommended BRAKE HOSE REPLACEMENT See General Warning o...

Page 68: ...Page 6 8 Discard the copper washers See following NOTE NOTE Place a pan under each caliper to collect brake fluid Plug each caliper to prevent debris from entering Do not allow brake fluid to contact...

Page 69: ...that will cause wear and damage 7 Perform all of the brake system inspections See Brake System Inspection on page 6 4 See preceding WARNING Rear Brake Hose Removal NOTE If any portion of the brake hos...

Page 70: ...ure 6 12 Page 6 10 and Figure 6 13 Page 6 10 located under the seat 5 Cut the wire ties securing the rear brake hoses to the rear suspension trailing arms Figure 6 1 Page 6 6 6 Pull the brake hose ass...

Page 71: ...hardware previously removed Figure 6 10 Page 6 10 and new wire ties Figure 6 1 Page 6 6 5 Secure the brake hoses banjo bolts and new copper washers to each rear caliper assembly Figure 6 9 Page 6 10...

Page 72: ...as necessary 1 Lift and support the front rear or entire vehicle and remove the wheel s See Lifting The Vehicle Section 3 Page 3 4 2 If replacing pads only skip to step 6 3 If replacing caliper remove...

Page 73: ...pads that contact the caliper A thin film may also be applied to the slide pins Always follow lubricant manufacturer s directions WARNING To reduce the possibility of diminished brake performance or...

Page 74: ...m Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System on page 6 16 CAUTION Worn or damaged brake discs cannot be machined to refinish them Replace as necessary 1 Remove the caliper See...

Page 75: ...Page 6 15 See following NOTE NOTE Place a plastic bag around the master cylinder to catch brake fluid before the brake hose is removed Once the hose is removed wrap the bag around the master cylinder...

Page 76: ...ened Vacuum bleeding is the recommended way to remove air from a brake system filled with DOT 5 silicone brake fluid If a vacuum brake bleeding tool is not available manually bleeding the system can b...

Page 77: ...It is important to have the vehicle sitting level and safely supported on jack stands before the manual bleeding procedure is performed See following WARNING WARNING Do not bleed brakes with only one...

Page 78: ...ervoir See following NOTE NOTE Do not allow the brake fluid in the master cylinder reservoir to fall below the MIN level mark at any time during the brake bleeding procedure 11 Once the caliper is ble...

Page 79: ...vehicle from rolling 2 Remove handle grip and loosen the set screw that locks the adjustment knob at the end of the park brake handle Figure 6 22 Page 6 20 3 Turn the adjustment knob to provide slack...

Page 80: ...h ferrule from the caliper bracket Figure 6 25 Page 6 20 7 Move the cable down and toward the rear of the vehicle to remove the cable end from the caliper park brake lever Figure 6 26 Page 6 20 1033 F...

Page 81: ...the handle assembly rest on the floorboard Figure 6 29 Page 6 21 Be sure to retain the spacer that fits between the sides of the handle assembly Figure 6 30 Page 6 21 and Figure 6 31 Page 6 21 12 Remo...

Page 82: ...move the remaining park cable in the same manner PARK BRAKE CABLE INSTALLATION WARNING When replacing cables both park brake cables on a vehicle must have the same part number The part number is stamp...

Page 83: ...amps And Short Spacer But Do Not Tighten 4 Attach the compensator link to the park brake handle with clevis pin washer and cotter pin Figure 6 40 Page 6 24 and Figure 6 41 Page 6 24 5 Route the cable...

Page 84: ...spacer that fits between the sides of the handle assembly Figure 6 30 Page 6 21 and Figure 6 31 Page 6 21 6 Remove the cotter pin Figure 6 32 Page 6 22 washers and clevis pin that attaches the compens...

Page 85: ...l surface To avoid injury or property damage ensure that the path of the vehicle is clear before the vehicle is pushed NOTE Adjust rear brake calipers park brake levers before adjusting park brake cab...

Page 86: ...e adjustment knob 1 4 turn Repeat as necessary until effort to apply park brake is acceptable and vehicle holds on a substantial grade 30 6 Release the park brake handle and engage it again The vehicl...

Page 87: ...eering wheel retaining bolt 18 Figure 7 1 Page 7 2 5 Remove the steering wheel See following NOTE NOTE The steering wheel has a tapered hex fitting A steering wheel puller CC P N 102061201 may be requ...

Page 88: ...ighten to 37 ft lb 50 N m 3 Install the steering wheel center cap by aligning the two pins on the cap with the two holes in the wheel 4 Connect battery and spark plug wire s See Connecting the Battery...

Page 89: ...STEERING AND FRONT SUSPENSION Steering Column 7 13 11 5 4 12 3 7 2 14 6 5 9 8 000896 001 000896 001 Figure 7 3 Steering System 2009 2012 XRT 950 Maintenance and Service Manual Page 7 3...

Page 90: ...must be aligned with the bolt hole in the universal joint before sliding the spline into the universal joint While holding the steering column in place attach it to the frame using bolts and nuts 4 a...

Page 91: ...loor turn the steering wheel from stop to stop While turning feel for any binding clunking or tight loose spots Listen for unusual noises 3 2 Replace the rack and pinion as an assembly if any damage i...

Page 92: ...LLATION 1 For ease of assembly and to prevent corrosion apply a light coat of anti seize and lubricating compound to the splines of the pinion shaft 2 Insert the pinion shaft into the universal joint...

Page 93: ...same height as the center of each hub Measure the distance between the marks Figure 7 8 Page 7 7 See following NOTE NOTE The front measurement must be more than the rear measurement 4 Subtract the re...

Page 94: ...remove the front wheels See Lifting The Vehicle Section 3 Page 3 4 4 Remove the pinch bolt and lock nut that secures the strut in the steering knuckle Figure 7 11 Page 7 8 5 Remove the two lock nuts t...

Page 95: ...age 8 2 1011 Figure 7 14 Align Tab and Slot STEERING KNUCKLE REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 2 Pry out the thin axle nut...

Page 96: ...ALLATION 1 Install a new ball joint if necessary See Ball Joint Removal on page 7 11 2 Slide the steering knuckle onto the front strut Figure 7 13 Page 7 8 Align the tab on the strut with the slot in...

Page 97: ...all new A arm bushings if necessary See following NOTE NOTE The urethane bushings fit tightly It may be necessary to press them into place Use the assembly bolts and large flat washers to force the bu...

Page 98: ...ing knuckle See Steering Knuckle Installation on page 7 10 5 Check wheel alignment See Wheel Alignment on page 7 7 FRONT WHEEL BEARINGS AND HUBS See General Warning on page 1 2 FRONT WHEEL FREE PLAY I...

Page 99: ...lly seated Figure 7 21 Page 7 13 See following CAUTION CAUTION To prevent bearing damage only push against the outer race to install bearing 3 Lubricate inner race of bearing and press hub in until fu...

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Page 101: ...ounted on the wheels with regard to which side of the vehicle they will be used on The arrow molded on the sidewall indicates designed rotation when vehicle is moving forward Figure 8 1 Page 8 1 See f...

Page 102: ...end of the vehicle in General Warning on page 1 2 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and tighten the lug nuts using a crisscross pattern until they are sn...

Page 103: ...3 Detail B See following CAUTION CAUTION To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pull the bead from...

Page 104: ...e See Vehicle Specifications on page 2 1 The three point contact wall floor and hand will help ensure that beads snap into place and form a proper seal as the tire is inflated Figure 8 3 Page 8 4 See...

Page 105: ...r wheel See Lifting The Vehicle Section 3 Page 3 4 3 Raise the cargo bed and secure with the bed locking pin See Cargo Bed Section 4 Page 4 20 4 Remove the bolt securing the rear shock absorber to the...

Page 106: ...icle Section 3 Page 3 4 3 Remove the hardware securing the lateral link to the chassis 4 Remove the hardware securing the lateral link to the trailing arm Figure 9 4 Page 9 2 and Figure 9 5 Page 9 2 1...

Page 107: ...groove in the halfshaft Figure 9 7 Page 9 3 and loosen the axle nut Figure 9 8 Page 9 3 951 Figure 9 7 Undo Staked Flange Of Axle Nut 1066 Figure 9 8 Loosen Axle Nut 3 Lift and support the rear of veh...

Page 108: ...e trailing arm Figure 9 4 Page 9 2 and Figure 9 5 Page 9 2 11 Remove the axle nut and push the halfshaft out of the hub 12 Remove the lock nut and bolt securing the front of the trailing arm to the ch...

Page 109: ...e halfshaft Figure 9 7 Page 9 3 and loosen the axle nut Figure 9 8 Page 9 3 3 Lift and support the rear of vehicle and remove the wheel See Lifting The Vehicle Section 3 Page 3 4 4 Raise the cargo bed...

Page 110: ...o bore until fully seated Figure 9 12 Page 9 6 See following CAUTION CAUTION To prevent bearing damage only push against the outer race to install bearing 3 Lubricate inner race of bearing and press h...

Page 111: ...1 4 WHEEL ALIGNMENT Rear wheel alignment consists of adjusting the camber toe in and thrust angle of the rear wheels by shortening and or lengthening the lateral links See Toe Out Measurement on page...

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Page 113: ...h Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn key switch to the OFF position remove the key place the Forward Reverse handle in the NEUTRAL p...

Page 114: ...ts and screws are tight Check hose clamps for tight fit Safety and information decals Check to ensure that all safety and information decals are in place and can be read easily See Owner s Manual ROPS...

Page 115: ...reverse buzzer should sound as a warning when the Forward Reverse handle is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel Acc...

Page 116: ...rential and Rear Transaxle on page 10 11 Monthly service by owner or trained technician General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Battery Clean termi...

Page 117: ...tighten if necessary Fuel filters Replace Dispose of used filters properly Clutch cover vent inlet filter if equipped Replace Dispose of used filters properly Annual service by trained technician only...

Page 118: ...ery 50 hours of operation or semiannually whichever comes first Driveshafts and bearing blocks 2 Chassis Lube EP NLGI Grade 2 Change every 100 400 hours of operation or semiannually whichever comes fi...

Page 119: ...gine with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick Figure 10 2 See following CAUTION CAUTION Do not remove dipstick while engi...

Page 120: ...ocket or wrench to remove the drain plug 1 Figure 10 4 Turn the plug counterclockwise and drain the engine oil into the pan See following WARNING WARNING Do not attempt to change engine oil when the e...

Page 121: ...n angle then slide the open area of the container up and under the oil filter before removal Position the port of the plastic container so oil will be directed into the oil pan A drip guard can be mad...

Page 122: ...oil capacity Doing so will decrease engine performance or result in damage to the engine 1 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 2 With the Fo...

Page 123: ...re brush or other suitable tool 3 If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug with an OEM replacement Spark Plug Torque 180 in lb 20 Nm SPARK P...

Page 124: ...cle operation The magnetic drain plug is included in the design to collect the metal particles generated from the gear break in process This is an established process and is not detrimental to gear se...

Page 125: ...Filter changes should not exceed the recommended interval See Periodic Service Schedule on page 10 3 More frequent service may be required in extremely dirty operating environments In the event of a l...

Page 126: ...ir cleaner assembly into the air filter housing 3 Place the housing cover on the top of the air filter housing 4 Secure the housing cover with both retaining clips 5 Replace the center plastic access...

Page 127: ...els and fuels that are blended with alcohol 2 Replace the fuel cap Ensure that the cap is tightened securely 3 Clean any spilled fuel from the cap or around the fuel cap area 1 2 816 Figure 10 15 Fuel...

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Page 129: ...tem and the electrical circuits of the system ELECTRICAL SYSTEM The electrical system on this gasoline key start vehicle is 12 volts DC with negative ground to frame It consists of the following circu...

Page 130: ...g Diagram TROUBLESHOOTING AND ELECTRICAL SYSTEM WIRING DIAGRAM HEAD LIGHTS Diode 1 WD1031003A L Figure 11 1 Wiring Diagram XRT 950 Initial Production Page 11 2 2009 2012 XRT 950 Maintenance and Servic...

Page 131: ...G AND ELECTRICAL SYSTEM Wiring Diagram 11 W35 16 _ BLK Diode 4 Diode 2 Diode 3 WD1031003A R Figure 11 2 Wiring Diagram XRT 950 Initial Production Continued 2009 2012 XRT 950 Maintenance and Service Ma...

Page 132: ...ing Diagram TROUBLESHOOTING AND ELECTRICAL SYSTEM HEAD LIGHTS Diode 1 WD1031003B L Figure 11 3 Wiring Diagram XRT 950 2009 to Early 2012 Model Year Page 11 4 2009 2012 XRT 950 Maintenance and Service...

Page 133: ...ELECTRICAL SYSTEM Wiring Diagram 11 W35 16 _ BLK Diode 4 Diode 2 Diode 3 WD1031003B R Figure 11 4 Wiring Diagram XRT 950 2009 to Early 2012 Model Year Continued 2009 2012 XRT 950 Maintenance and Servi...

Page 134: ...SHOOTING AND ELECTRICAL SYSTEM TO FRONT DIFFERENTIAL WD1038736A L Figure 11 5 Wiring Diagram XRT 950 with Auto Locking Front Differential Starting Mid 2012 Model Year Page 11 6 2009 2012 XRT 950 Maint...

Page 135: ...ELECTRICAL SYSTEM Wiring Diagram 11 WD1038736A R Figure 11 6 Wiring Diagram XRT 950 with Auto Locking Front Differential Starting Mid 2012 Model Year Continued 2009 2012 XRT 950 Maintenance and Servi...

Page 136: ...r carburetor dirty or clogged fuel filter Fuel System section Carburetor improperly adjusted See the Briggs Stratton Vanguard engine manual CC P N 103568101 Starter failure See the Briggs Stratton Van...

Page 137: ...ly adjusted Engine section Engine overheats Carburetor is too lean check main jet size See the Briggs Stratton Vanguard engine manual CC P N 103568101 Excessive carbon deposits on piston head or in co...

Page 138: ...Float needle valve not functioning properly See the Briggs Stratton Vanguard engine manual CC P N 103568101 Starter control circuit is not operating Test Procedure 5 Starter Control Circuit on page 1...

Page 139: ...muffler mounting clamp Exhaust System section Damaged drive belt Clutches section Damaged drive clutch Clutches section Damaged driven clutch Clutches section Excessive vehicle vibration RPM setting...

Page 140: ...f Test Procedures 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circuit 5 Starter Control Circuit 6 Starter Solenoid 7 Wire Harness Diodes 8 Neutral Switch Transaxle 9 Wire Continuity 10 Charg...

Page 141: ...o obtain a higher specific gravity Figure 11 7 Page 11 14 See following CAUTION CAUTION Do not allow battery acid from battery caps or hydrometer to drip onto the body Battery acid will cause permanen...

Page 142: ...190 1 210 50 1 160 1 180 25 If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between...

Page 143: ...tely 9 6 VDC 6 If the battery voltage is acceptable or if the electrical problem continues after the battery has been replaced test the electrical circuits 7 If the voltage reading exceeds 9 6 volts a...

Page 144: ...ive battery terminal and the two 14 gauge black wires w39 and w104 for damage Repair or replace as required 4 Check the engine ground wire w91 located on the side of the engine block for corrosion loo...

Page 145: ...orrectly and is tight If it is not repair or replace as necessary 4 Remove the key switch See Key Switch Removal on page 12 7 5 Set the multimeter to 200 ohms 6 Turn the key switch ON Place the red pr...

Page 146: ...st Accessory Terminal 1700 30100 10375 Figure 11 14 Key Switch Test Starter Circuit TEST PROCEDURE 5 Starter Control Circuit See General Warning on page 1 2 1 Turn the key switch OFF Place the Forward...

Page 147: ...ect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 2 Disconnect all wires connected to the solenoid Figure 11 16 Page 11 19 and Figure 11 17 Page 11 19 1076...

Page 148: ...es TROUBLESHOOTING AND ELECTRICAL SYSTEM 1155 Figure 11 18 Continuity Between Small Terminal and Ground 1156 Figure 11 19 Continuity Between Large Terminals Page 11 20 2009 2012 XRT 950 Maintenance an...

Page 149: ...1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000...

Page 150: ...has been replaced Open Engine will not start Diode 4 w112 and w130 Carburetor solenoid control powers carburetor solenoid when key switch is in the START position Closed Starter will be activated whe...

Page 151: ...e fuel gauge hour meter 6 Disconnect the 18 gauge green wire w30 from the park brake limit switch mounted on the side of the park brake handle assembly 7 Disconnect the 18 gauge black wire w118 from t...

Page 152: ...he multi pin connector from the key switch 3 Disconnect the two bullet connectors Figure 11 25 Page 11 24 and Figure 11 26 Page 11 24 the charge coil plug with the two yelllow wires Figure 11 27 Page...

Page 153: ...gauge green wire w110 8 The reading should indicate an over limit no continuity If the diode conducts current shows continuity with the meter probes connected as described the diode has failed and mu...

Page 154: ...to the diode test function 5 Connect the black probe of the multimeter to the end of the 16 gauge green wire w110 6 Connect the red probe of the multimeter to the male side of the carburetor solenoid...

Page 155: ...the Forward Reverse handle in the FORWARD position The multimeter should indicate no continuity 4 Check for continuity on the switch contacts with the Forward Reverse handle in the NEUTRAL position T...

Page 156: ...sconnecting the Battery Gasoline Vehicles on page 1 4 2 Disconnect the 2 pin connector from the voltage regulator Figure 11 37 Page 11 28 3 Measure the resistance of the charge coil on the two yellow...

Page 157: ...perform the test on the remaining spark plug 6 There should be a strong blue spark between the probes of the spark gap tester when both spark plug circuits are tested If there is no spark on either of...

Page 158: ...ected the engine will not stop running immediately after the key switch is turned to the OFF position It may be necessary to pull and hold the choke handle until the engine stops running 4 Also check...

Page 159: ...test procedure 1 Check the carburetor solenoid coil circuit 1 1 Turn the key switch OFF Place the Forward Reverse handle in NEUTRAL and set the park brake Chock the wheels 1 2 Disconnect the red wire...

Page 160: ...the resistance reading is incorrect replace the carburetor solenoid See the Briggs Stratton Vanguard engine manual CC P N 103568101 WAR NING WAR NING 1145 Figure 11 44 Check for Voltage Between Harnes...

Page 161: ...ding unit 3 With a multimeter set to 2k ohms place the red probe of the multimeter on the center post of the sending unit Place the black probe on the ground connection of the sending unit Figure 11 4...

Page 162: ...e positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 5 Set a multimeter to 20 volts DC and place the red probe on the 2 terminal of the f...

Page 163: ...rt the engine and let it idle See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 4...

Page 164: ...et See General Warning on page 1 2 NOTE Keep the battery connected while performing this test procedure 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Inspect the wires at the light bul...

Page 165: ...ning on page 1 2 NOTE The front differential disable switch is only used with the auto locking front differential starting mid 2012 model year 1 Disable the vehicle See Disabling the Vehicle on page 1...

Page 166: ...e the vehicle See Disabling the Vehicle on page 1 3 2 Check for proper wiring and tight connections at the front differential limit switch 3 Move accelerator pedal and listen for an audible click from...

Page 167: ...on page 1 2 The neutral switch 1 is located on top of the transaxle housing Figure 12 1 Page 12 2 TESTING THE NEUTRAL SWITCH See Test Procedure 8 Neutral Switch Transaxle on page 11 26 NEUTRAL SWITCH...

Page 168: ...located on the bottom of the carburetor TESTING THE CARBURETOR SOLENOID See Test Procedure 16 Carburetor Solenoid Circuit on page 11 31 CARBURETOR SOLENOID REMOVAL 1 Disconnect battery and spark plug...

Page 169: ...nect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 VOLTAGE REGULATOR See General Warning on page 1 2 TESTING THE VOLTAGE REGULATOR See Test Procedure 11 Voltag...

Page 170: ...ting screws Figure 12 6 Page 12 4 Tighten screws to 30 in lb 3 4 N m 2 Connect the 2 pin connector and the red wire of the voltage regulator 3 Connect battery and spark plug wire s See Connecting the...

Page 171: ...12 7 Page 12 5 4 Press the retaining tabs and remove the warning light from the instrument panel 1 7 4 6 5 2 3 1167 Figure 12 7 Instrument Panel Electrical Components WARNING LIGHT INSTALLATION 1 Pus...

Page 172: ...ne Vehicles on page 1 4 2 Raise the hood and remove the access panel 3 Disconnect the wires from the fuel gauge hour meter 2 Figure 12 7 Page 12 5 4 Remove the mounting clip 3 that secures the gauge m...

Page 173: ...e removal procedure to install switch in the instrument panel Figure 12 7 Page 12 5 Tighten the key switch nut 5 firmly 2 From under the hood connect the multi pin connector to the key switch 3 Instal...

Page 174: ...sconnecting the Battery Gasoline Vehicles on page 1 4 2 Raise the hood and remove the access panel 3 Press the upper and lower retaining tabs and push the front differential disable switch out of the...

Page 175: ...ighten the nuts 2 to 4 in lb 0 5 N m See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened the switch could become damaged 2 Move the accelerator pedal back...

Page 176: ...ARGE COIL See General Warning on page 1 2 It is recommended that the ignition coil and charge coil be thoroughly tested prior to replacement TESTING THE IGNITION COIL AND CHARGE COIL See Test Procedur...

Page 177: ...e See Disabling the Vehicle on page 1 3 2 From the front of the vehicle reach under the cowl and turn the connector harness halogen bulb assembly clockwise one quarter turn Figure 12 8 Page 12 11 3 Re...

Page 178: ...side of the silver stripe 4 Cut the wires attached to each side of the diode and discard the diode DIODE INSTALLATION 1 Slide a piece of heatshrink tubing over one of the wire ends where the diode wil...

Page 179: ...that the battery clamp will fit correctly Testing The Battery See Test Procedure 1 Battery on page 11 12 Preventive Maintenance 1 To keep the battery in good operating condition remove corrosion imme...

Page 180: ...PER MILLION Suspended matter Trace Total solids 100 0 Calcium and magnesium oxides 40 0 Iron 5 0 Ammonia 8 0 Organic matter 50 0 Nitrates 10 0 Nitrites 5 0 Chloride 5 0 Battery Removal See General War...

Page 181: ...wire s See Disconnecting the Battery Gasoline Vehicles on page 1 4 3 Fully charge the battery prior to storage 4 Store in a cool dry area The colder the area in which the battery is stored the less t...

Page 182: ......

Page 183: ...Battery Gasoline Vehicles on page 1 4 4 Lift and support the entire vehicle on jack stands and remove the rear wheels See Lifting The Vehicle Section 3 Page 3 4 5 Remove the seat bottom 6 Remove the...

Page 184: ...pipe See Exhaust Pipe Removal Section 15 Page 15 2 17 Disconnect all wire harness leads Figure 13 3 Page 13 2 Figure 13 4 Page 13 2 Figure 13 5 Page 13 2 and Figure 13 6 Page 13 2 red battery cable at...

Page 185: ...10 Page 13 3 979 Figure 13 9 Loosen Anchor To Release Cable Sheath 980 Figure 13 10 Maneuver Choke Cable End Out Of Choke Lever 21 Disconnect fuel hose from fuel pump plug the end of hose to prevent f...

Page 186: ...13 Engine Removal ENGINE 988 Figure 13 11 Remove Engine Mounting Hardware Page 13 4 2009 2012 XRT 950 Maintenance and Service Manual...

Page 187: ...on page 5 12 14 Attach and adjust the choke cable Figure 13 10 Page 13 3 and Figure 13 9 Page 13 3 15 Connect the wire harness leads Figure 13 3 Page 13 2 Figure 13 4 Page 13 2 Figure 13 5 Page 13 2...

Page 188: ...rly 2012 Model Year on page 5 7 If the throttle bellcrank contacts the positive stop tab correctly proceed to the next step 2 Perform idle speed adjustment procedure See Idle Speed Adjustment on page...

Page 189: ...an idle adjustment screw It only works in conjunction with the idle spring and the tang it is anchored to 4 2 At the governor make sure there is no tension on the main governor spring 2 Figure 13 14 P...

Page 190: ...nsion and idle speed bend the tang to the left towards front of vehicle 1 1 2 1460 Figure 13 17 Idle Spring Tang Location 1461 Figure 13 18 Bend Idle Spring Tang To Vary Idle Speed 8 Once the engine i...

Page 191: ...ot attempt to move forward return the vehicle to service If it does attempt to move forward see Vehicle Creep on page 13 5 HIGH SPEED ADJUSTMENT WARNING To prevent engine overspeeding the governor and...

Page 192: ...governor spring tang 1 located on the bottom of the throttle bellcrank Figure 13 21 Page 13 10 Make minor adjustments at a time Be careful not to touch the hot exhaust manifold See preceding WARNING T...

Page 193: ...20 1 3 Remove the exhaust pipe heat shield 1 4 Push accelerator pedal to the floor and hold 1 5 Verify the throttle bellcrank makes a positive stop against the mounting bracket tab Figure 13 30 Page...

Page 194: ...the governor to modulate engine speed at idle and prevent stalling See following NOTE NOTE The idle stop screw is not an idle adjustment screw It only works in conjunction with the idle spring and th...

Page 195: ...vehicle Figure 13 28 Page 13 13 To increase 2 spring extension and idle speed bend the tang to the left towards front of vehicle 1 1 2 2514 Figure 13 27 Idle Spring Tang Location 2515 Figure 13 28 Ben...

Page 196: ...attempt to move forward return the vehicle to service If it does attempt to move forward see Vehicle Creep on page 13 11 HIGH SPEED ADJUSTMENT WARNING To prevent engine overspeeding the governor and...

Page 197: ...vernor spring tang located on the bottom of the throttle bellcrank Figure 13 31 Page 13 15 Make minor adjustments at a time Be careful not to touch the hot exhaust manifold See preceding WARNING To re...

Page 198: ...3 16 979 Figure 13 32 Loosen Anchor To Release Choke Cable Sheath 980 Figure 13 33 Maneuver Choke Cable End Out Of Choke Lever 7 Loosen governor lever nut 1 Figure 13 34 Page 13 17 8 Push governor lev...

Page 199: ...h Early 2012 Model Year on page 13 5 or Engine RPM Adjustment From Early 2012 Model Year on page 13 11 16 Perform high speed adjustment procedure See Engine RPM Adjustment Through Early 2012 Model Yea...

Page 200: ......

Page 201: ...l lines and fire FUEL FILTER See General Warning on page 1 2 One in line filter is installed between the fuel tank and the fuel pump Fuel filters fuel lines and the fuel tank vent should be inspected...

Page 202: ...nual CC P N 103568101 CARBURETOR JETTING The Briggs Stratton Vanguard engine is equipped with a carburetor that has a fixed jet The fixed jet does not require adjustment The size of the main jet is de...

Page 203: ...the orange wire 8 Figure 14 1 Page 14 4 Retain the hardware 4 Remove the hex head plastic thread screw 2 securing the black ground wire 7 to the fuel level sending unit and remove the black ground wir...

Page 204: ...14 Fuel Level Sending Unit FUEL SYSTEM 4 11 5 9 8 14 6 13 10 7 2 3 12 000883 001 000883 001 Figure 14 1 Fuel Tank and Components Page 14 4 2009 2012 XRT 950 Maintenance and Service Manual...

Page 205: ...the mounting holes in the gasket are aligned properly with the mounting holes on the fuel tank 2 Feed a new sending unit rheostat arm and float 4 into the fuel tank The rheostat arm and float should b...

Page 206: ...a crisscross pattern to tighten the hardware to 9 in lb 1 N m If the hardware cannot be tightened to 9 in lb 1 N m the fuel tank must be replaced See following CAUTION CAUTION Do not overtighten the s...

Page 207: ...ent fuel spillage and secure hose out of the way 6 Disconnect the vent tube from the fuel tank 2 Figure 14 3 Page 14 8 7 Disconnect all wire harness leads from the fuel level sender Do not remove the...

Page 208: ...9 Figure 14 5 Retract Rubber Bumper FUEL TANK STORAGE OR DISPOSAL 1 Remove the cap from the tank and thoroughly rinse it with water The cap may be discarded or kept as a spare 2 Use a well ventilated...

Page 209: ...fuel tank 11 Ensure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 3 2 Page 3 3 12 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicle...

Page 210: ...m from vehicle 3 Remove hose clamps securing three hoses to canister and disconnect hoses Figure 14 6 Page 14 10 4 Push pull the canister to force it from its mounting bracket CARBON CANISTER INSTALLA...

Page 211: ...e to heed this warning could result in severe burns 3 Remove the nut and bolt securing the bottom of the muffler to the chassis Figure 15 2 Page 15 1 4 Pull the muffler off of the exhaust pipe and rem...

Page 212: ...gure 15 3 Page 15 2 5 Remove the exhaust pipe nuts at the cylinder heads Figure 15 4 Page 15 2 and pull exhaust pipe from vehicle 1023 Figure 15 3 Remove Exhaust Pipe Heat Shield 989 Figure 15 4 Exhau...

Page 213: ...l 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant FRONT DIFFERENTIAL REMOVAL See General Warning on page 1 2 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicl...

Page 214: ...the driver side until the passenger side half shaft can be easily disengaged from the differential output shaft splines Figure 16 6 Page 16 2 1001 Figure 16 5 Front Differential mounting hardware rem...

Page 215: ...senger side opening in the frame Figure 16 9 Page 16 3 1008 Figure 16 9 Front Differential differential removal 1184 Figure 16 10 Front Differential differential removed from vehicle FRONT DIFFERENTIA...

Page 216: ...gaged onto the passenger side differential output shaft splines 8 Center the differential on the mounting plate on the front frame 9 Secure the differential to the mounting plate on the front frame Ti...

Page 217: ...5 951 Figure 16 13 Undo Staked Flange Of Axle Nut 1066 Figure 16 14 Loosen Axle Nut 3 Lift and support the front of vehicle and remove the wheel See Lifting The Vehicle Section 3 Page 3 4 4 Using a pi...

Page 218: ...it is installed 2 Tighten the axle nut to 142 ft lb 193 N m and then stake the nut to the groove in the halfshaft 3 Install wheel and lower vehicle See Wheel Installation Section 8 Page 8 2 4 Connect...

Page 219: ...with Optional PTO Front RATIOS Final Drive Ratio Forward 18 186 1 Reverse 34 371 1 PTO Ratio 4x4 version only Forward 3 529 1 Reverse 6 669 1 Approved Lubricant SAE 10W 30 API Service Class SF SG SH S...

Page 220: ...See Clutches Section 18 Page 18 1 8 Remove the exhaust pipe heat shield and muffler See Exhaust System Section 15 Page 15 1 9 Disconnect the wire harness leads from the neutral switch and oil pressur...

Page 221: ...13 1 Pry the driveshaft free from the cir clip on the transaxle output shaft Figure 17 10 Page 17 4 13 2 Remove the bolt and nut securing the driveshaft in the universal joint Figure 17 11 Page 17 4 1...

Page 222: ...me but do not remove the hardware at this time Figure 17 14 Page 17 4 and Figure 17 15 Page 17 4 1106 Figure 17 14 Front Transaxle Mount Hardware 1295 Figure 17 15 Rear Transaxle Mount Hardware 15 Pla...

Page 223: ...ove Rear Subframe Hardware 1095 Figure 17 19 Lower Subframe With Floorjack 18 Carefully lower the subframe to the floor Figure 17 19 Page 17 5 19 Use a pry bar to disconnect the halfshafts from the tr...

Page 224: ...7 21 Page 17 5 10 Raise the subframe and secure to chassis mounting straps with the hardware Tighten the rear subframe hardware to 32 ft lb 43 4 N m and the front subframe bolts to 50 ft lb 67 8 N m 1...

Page 225: ...rear shock absorber See Rear Shock Removal Section 9 Page 9 1 6 Use a pry bar to disconnect the halfshaft from the transaxle Figure 17 20 Page 17 5 and Figure 17 21 Page 17 5 7 Remove the axle nut an...

Page 226: ...erify cable functions as intended FOUR WHEEL DRIVE CABLE ADJUSTMENT THROUGH EARLY 2012 MODEL YEAR See General Warning on page 1 2 NOTE An open front differential is used through early 2012 model year...

Page 227: ...LOCK position Figure 17 24 Page 17 9 1 2 1 Locking Pin 2 Bed Locking Pin Holes 1463 Figure 17 24 Place Handle in the Unlocked Position K 00221 Figure 17 25 Bed Locking Pin 5 At the transaxle the rear...

Page 228: ...ever 2 should stay in the locked position 2 1 1466 Figure 17 28 Differential Lock Lever and Spring with Cable in LOCK Position 10 Rotate the passenger side rear tire by hand The differential should lo...

Page 229: ...ed will not be properly balanced If either clutch is dropped assume that it is damaged and replace it To remove disassemble and assemble the drive and driven clutches properly the following tools shou...

Page 230: ...d remove the driver side rear wheel See Lifting The Vehicle Section 3 Page 3 4 3 Raise the cargo bed and secure with the bed locking pin See Cargo Bed Section 4 Page 4 20 4 Remove the exhaust pipe hea...

Page 231: ...s See Connecting the Battery Gasoline Vehicles on page 1 4 DRIVE BELT The drive belt should be inspected periodically for wear and glazing See Periodic Service Schedule Section 10 Page 10 3 If it is...

Page 232: ...ive Clutch 3 Driven Clutch 17 Threaded hole used to aid belt removal K 00199 Figure 18 4 Locate Threaded Hole In Driven Clutch 1119 Figure 18 5 Thread Service Bolt Into Driven Clutch To Expand Sheaves...

Page 233: ...ill also remain available for the previous drive clutch and driven clutch The new drive and driven clutches are backward compatible only if installed as a set See following CAUTIONS CAUTION To avoid u...

Page 234: ...and a dry lint free cloth to clean clutch parts See following CAUTION CAUTION Do not lubricate the drive clutch Lubricants attract dirt and dust which interfere with proper clutch operation Use only...

Page 235: ...the spring 5 stopper 4 and spring seat 3 off the fixed sheave 2 shaft DRIVE CLUTCH COMPONENT INSPECTION Inspect the weight blocks 7 and their seats in the moveable sheave 6 Figure 18 10 Page 18 8 Ther...

Page 236: ...18 Drive Clutch CLUTCHES 2 3 4 5 6 7 8 9 10 000901 001 Figure 18 10 Drive Clutch Exploded Page 18 8 2009 2012 XRT 950 Maintenance and Service Manual...

Page 237: ...heel Figure 18 12 Page 18 9 1017 Figure 18 11 Remove Fuel Pump Hardware 976 Figure 18 12 Remove Screws Securing Rotating Screen 3 3 Remove bolts securing fan shroud to engine Figure 18 13 Page 18 9 3...

Page 238: ...ith the clutches A clutch that has been dropped will not be properly balanced If either clutch is dropped assume that it is damaged and replace it DRIVEN CLUTCH REMOVAL 1 Disconnect battery and spark...

Page 239: ...CLUTCHES Driven Clutch 18 2 3 4 5 6 7 8 000901 002 NOTE Item 3 used till late 2011 model year Figure 18 17 Driven Clutch Exploded 2009 2012 XRT 950 Maintenance and Service Manual Page 18 11...

Page 240: ...2 Place the driven clutch onto the tool base with the cam 6 oriented up Figure 18 19 Page 18 12 1203 Figure 18 20 Place Alignment Marks On Cam and Both Sheaves 1202 Figure 18 21 Center Disassembly Too...

Page 241: ...18 13 7 Remove snap ring 8 Figure 18 23 Page 18 13 1205 Figure 18 24 Release Spring Tension 1206 Figure 18 25 Remove Cam And Spring 8 Slowly remove the compression handle Figure 18 24 Page 18 13 The...

Page 242: ...ring groove at end of shaft 9 Ensure mark on cam aligns with marks on sheaves Figure 18 20 Page 18 12 10 Install snap ring 8 Figure 18 23 Page 18 13 DRIVEN CLUTCH INSTALLATION 1 Ensure the splines on...

Page 243: ...faces on the inner clutch cover engine and transaxle are clean 2 Set the inner clutch cover into place on the transaxle and engine 3 Install new bolts finger tight into the transaxle first starting wi...

Page 244: ......

Page 245: ...6 14 brake disc and pad inspection 6 5 brake line inspection 6 4 brake line front installation 6 8 removal 6 8 brake line rear installation 6 11 removal 6 9 brake pad front installation 6 13 removal...

Page 246: ...10 assembly 18 14 disassembly 18 12 installation 18 14 removal 18 10 E electrical system circuits 11 1 key start 11 1 emissions evaporative carbon canister 14 9 engine installation 13 5 removal 13 1...

Page 247: ...10 removal 4 9 J jump starting using a booster battery 3 6 K key switch engine kill circuit testing 11 30 installation 12 7 removal 12 7 starter circuit testing 11 17 kill circuit engine testing 11 3...

Page 248: ...l alignment 9 7 T test procedures 1 battery 11 12 10 charge coil 11 28 11 voltage regulator 11 28 12 ignition test 11 29 13 engine kill circuit 11 29 14 grounded kill wire 11 30 15 key switch engine k...

Page 249: ...7 7 rear 9 7 wheel bearings and hub front inspection 7 12 installation 7 13 removal 7 12 rear inspection 9 5 installation 9 6 removal 9 5 wheel steering see steering wheel 7 1 wire continuity testing...

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